Introduction
Today, every single company desires profit, high productivity, value in the market. There are defect reduction targets' slogans in most of the factories, but the final goal should always remain zero defects. "POKA-YOKE" is a crucial element in defect removal. Poka-yoke is a total quality management concept that is associated with limiting errors at source itself. Poka-yoke is associated with "fool-proofing" or "mistake-proofing.". A poka-yoke is any idea creation or mechanism design in a total productive management process which assists operator to prevent (yokeru) errors (poka). Principal objective of Poka Yoke concept is to make entire system error proof which means no body can commit mistake though some one desires to make mistake sin tentionally. It removes the defects or faults. This word was invented by Shigeo Shingo during 1960sfor Toyota Production System part. The purpose of Poka-yoke is to make the process in such a way that errors are discovered and removed at once, getting rid of defects at their origin. A systematic process to develop Poka-Yoke countermeasures which involves three-step risk analysis to be controlled.
What Is Poka-Yoke
Poke-yoke (Mistake proofing) refers to the Japanese strategy of not just improving, but mistake-proofing in order to avoid defects (or Nonconformities) occurring in manufacturing operations. Poka-yoke is a preventive measure that aims at identification and removal of the special causes of variation in production processes, inevitably resulting in product defects or nonconformities. This was originally referred to as Idiot Proofing but it was realized that this name could hurt workers so the term Mistake Proofing was coined by Shigeo Shingo. Poka-yoke provides a policy and approach for preventing defects at the source. Poka-yoke solutions are not only inexpensive but also simple to comprehend and implement. Mistake proofing is one of the valuable tools to incorporate into any organization's Continuous improvement.
Need Of Poka-Yoke
When any company resolves to do the lean manufacturing then one of the aims is to minimize scrap because no one wants to pay for additional inventory due to scrap. According to lean manufacturing philosophy it emphasizes speed of production and productivity too. To keep pace with this philosophy of speed we must overcome defects and rework. To the profit percentage increase the cost pressures always prove to be headache for top management therefore they never tolerate ongoing errors like scrap, rework, lateness etc. rather they are looking to achieve value of zero in this area.
Technical Aspect of Poka-Yoke Method
Poka-Yoke method can be used to prevent causes, which will lead to next time errors and to perform low cost control whether to accept or not the product. It is not always 100% probability removal of all errors. in such instances it is the work of Poka-Yoke methods is detection as early as possible. Examine the process of defects formation of the product observed that between an error caused by the defect is still one, the possible possibility.
Methods Of Obtaining Poka Yoke
Poka yoke ideas are easy to be creative in operation and invention. Shingo says, "Defects will never be reduced if the workers involved do not modify operating methods when defects occur." Below are some of the easy ideas (tips) for avoiding errors: poka-yoke devices are easy and cost-effective. They comprise electronic devices that will not initiate the assembly process until the appropriate part has been fitted into the appropriate position as well as measures like altering the shape of the part or the fixture so that things could fit together only in the right.
Experimental Procedure
✓ Problem Identification: Determine specific defects or errors that must be avoided.
✓ Process Analysis: Chart the process and perform root cause analysis to determine where there are errors.
✓ Select Poka Yoke Type: Select the proper error-proofing.
✓ Design Solution: Create a simple, effective Poka Yoke device to avoid or detect errors.
✓ Prototype Testing: Construct and test prototypes to confirm that the device performs as desired.
✓ Implementation: Train the employees and incorporate the device into the production process.
✓ Monitor Effectiveness: Monitor error rates prior to and subsequent to the implementation to measure success.
✓ Feedback and Standardization: Collect user feedback, adjust as required, and standardize.
Result And Discussion
The outcome of this project proves the efficiency of poka-yoke methods in minimizing flaws, increasing efficiency, and promoting quality in a manufacturing line. The 66.7% reduction in flaws and 25% reduction in cycle time are ample gains that can contribute significantly to the bottom line of the organization. The use of poka-yoke methods also led to an 18.75% increase in first-pass yield, which means that the production line is delivering higher-quality products with fewer defects.
Conclusion
The outcome of this project proves the efficiency of poka-yoke methods in minimizing flaws, increasing efficiency, and promoting quality in a manufacturing line. The 66.7% reduction in flaws and 25% reduction in cycle time are ample gains that can contribute significantly to the bottom line of the organization. The use of poka-yoke methods also led to an 18.75% increase in first-pass yield, which means that the production line.
Author Bios:
1. C. Dineshbabu, AP/Mech
2. M. Prasanna – IV Mech
3. G.R. Saravanan – IV Mech
4. R. Saravananv – IV Mech
Comments
Post a Comment